Moulds for transforming plastic and composite materials and related transformation method

ABSTRACT

The invention concerns a mold for transforming plastic and/or composite materials, such as thermoplastic and thermosetting polymers and vulcanizable compounds, comprising a mold body ( 3, 3   a,    3   b ) provided with an impression ( 4, 4   a,    4   b ). The invention is characterized in that it comprises heating means which directly heat the material to be transformed or an intermediate surface impression adjacent to the material without using heat conductivity of the mold body ( 3   a,    3   b ) and/or of the impression ( 4, 4   a,    4   b ) to heat the material to be transformed.

[0001] The present invention relates to molds adapted to transforming plastic and composite materials, and the related transformation methods.

[0002] In the transformation of plastic and composite materials, and namely the transformation of reinforced or non-reinforced thermoplastic or thermosetting polymers, as well as vulcanizable compounds, there are numerous methods that consist of heating the material within a mold while pressurizing it, so that it can polymerize while taking on the mold impression. These transformation methods generally use the thermal conduction of the molds to bring the material to the temperature desired for its polymerization. Thus, the molds used are made from materials that conduct heat, on the one hand, and that withstand the temperature at which one wishes to heat the material, on the other hand.

[0003] The molds used in the prior art are therefore of two types: metal molds that conduct heat well and that easily withstand the high temperatures, and composite molds that only allow working at relatively low temperatures and with which one can only work certain plastic or composite materials that have low transformation temperatures. These various molds from the prior art have numerous drawbacks related to their implementation and to their use.

[0004] Metal molds are very expensive and require heavy investments. In addition, they rise in temperature and therefore cause problems in handling the demolded elements, problems in cooling and heating the elements and the molds, and therefore problems related to the cycle times. Also, the necessity of heating the entire mold requires a very substantial use of energy, particularly in the case of large sized elements. Composite molds are less expensive, but they are made of materials that do not resist high temperatures; therefore, they can only transform plastic and composite materials having a low transformation temperature. In addition, they degrade easily when the temperature rises, and they only allow a number of cycles that is very limited compared to metal molds.

[0005] The object of the present invention is to resolve the aforementioned drawbacks by means that are simple, easy to implement and inexpensive. It proposes a new generation of composite type molds for transforming plastic and composite materials which allow transforming the material at high temperatures without damaging the molds, and which allow a high number of cycles, while improving the duration of the cycle times, whose length is related to problems of raising the temperature of the molds and of the material. They also allow substantial energy savings compared to traditional metal molds.

[0006] In certain cases, these new molds further allow benefiting from a possibility of quick maintenance without requiring the replacement of the entire mold when the impression thereof is damaged.

[0007] In this manner, according to its main characteristic, the mold for the transformation of plastic and/or composite materials, such as thermoplastic polymers, thermosetting polymers and vulcanizable compounds, is of the type comprising a mold body provided with an impression, and it is characterized in that it comprises heating means that directly heat the material to be transformed or an intermediary surface impression adjacent to said material, without using the thermal conductivity of the mold body and/or of the impression to heat the material to be transformed.

[0008] According to another characteristic of the mold of the invention for transforming plastic and/or composite materials, the impression is constituted of a material that prevents the transfer of calorific energy from the material to the mold body, and vice-versa.

[0009] According to embodiments of the mold, the material forming the impression is a mineral resin constituted of the association or combination of non-organic components.

[0010] According to another characteristic of the mold of the invention for transforming plastic and/or composite materials, the latter comprises complementary insulating means formed by at least one reflective sheet arranged in the material forming the impression, or between said material and the one forming the mold body.

[0011] According to an additional characteristic of the mold of the invention, the latter is characterized in that the heating means are of the electrokinetic or magnetodynamic type, and send an electric current directly or by induction in the material or in the surface impression.

[0012] According to embodiments of the mold of the invention for transforming plastic and/or composite materials, the latter comprises a surface impression made of an electrically conductive material and arranged between the material and the impression in order to cover said impression at least partially.

[0013] According to these embodiments, the surface impression is made by the electroplating of a metal or of several layers of various metals, by the machining of a metal or an alloy, or by the shaping of a strip made of a forgeable or malleable metal alloy, by the plasma spraying of metals or ceramics, or by the vacuum or chemical vapor phase deposition of metals or ceramics.

[0014] According to another characteristic of the mold for transforming plastic and/or composite materials of the invention, it comprises a mold body made of two portions, a lower portion or baseplate that has a recessed impression and an upper portion or punch that has an impression in relief.

[0015] According to an additional characteristic of the mold of the invention, the latter is characterized in that it comprises a device for pressurizing the material to be transformed which has a flexible membrane.

[0016] According to an embodiment of the mold for transforming plastic and/or composite materials, the membrane is arranged about the impression in relief in order to be pressurized due to means for circulating air.

[0017] According to this embodiment, the membrane is made of silicone, fluoroelastomer, or any other extensible material that resists high temperatures.

[0018] According to an additional characteristic of the mold of the invention, the latter is characterized in that it has means for cooling the material.

[0019] According to an embodiment of the mold for transforming plastic and/or composite materials, the cooling means are at least partially formed by the pressurizing device that allows the circulation of fresh air between the impression and the membrane.

[0020] Furthermore, the mold for transforming plastic and/or composite materials can comprise complementary cooling means that separate the surface impression and/or the material from the mold impression in order to allow the circulation of fresh air therebetween.

[0021] According to another characteristic of the mold of the invention, the latter is characterized in that the mold body is made of cast resin.

[0022] In addition, the invention also relates to a method for transforming plastic or composite materials that is characterized in that it comprises a main step which consists of directly heating in a mold the material or a surface impression adjacent thereto without using the thermal conductivity of the mold body.

[0023] Other characteristics and advantages of the invention will become apparent from the following description, with reference to the attached drawings that are given only as non-limiting examples.

[0024] FIGS. 1-8 show various molds of the invention as well as their method of use.

[0025]FIG. 1 shows a mold in perspective.

[0026]FIGS. 2a-2 d schematically show a complete cycle of transforming a material in a mold of the invention.

[0027]FIG. 2a shows the heating step.

[0028]FIG. 2b shows the pressurizing step.

[0029]FIG. 2c shows the cooling step.

[0030]FIG. 2d shows the demolding of the element obtained.

[0031]FIGS. 3a-3 d and 4 a-4 d show, in similar views, the transformation cycle with two other alternative molds of the invention.

[0032]FIG. 5 shows in perspective a second embodiment of a mold of the invention.

[0033]FIGS. 6a-6 d show in a transverse cross-section the different steps of a molding method of the invention, the positioning, the heating, the temperature control and the cooling, respectively.

[0034]FIGS. 7a-7 d show in a transverse cross-section the heating, the temperature control, the cooling and the complementary cooling and demolding step of the method of the invention.

[0035]FIG. 8 shows in perspective an alternative construction of the mold of the invention.

[0036] The present invention relates to a new generation of molds adapted to transforming plastic and composite materials. This new generation of molds is adapted to transforming all thermoplastic polymers, such as polypropylene, polyethylene, polyamides, and all thermosetting polymers, such as epoxy and polyester, for example. Naturally, these polymers can be reinforced or non-reinforced with short, long or continuous carbon fibers, glass fibers, aramid, metallic, mineral or vegetable fibers. In addition, it also allows the transformation of vulcanizable compounds, such as rubber, for instance. All of these plastic and composite materials that are capable of being transformed can be in several forms, such as, for example, in the form of fabrics or layers, in the form of tubular braids, or even in the form of powders or granulates, without leaving the scope of protection of the invention. These molds, generally designated by the reference numeral (1), have heating means (MC) adapted to heat the plastic and/or composite material (2) to be transformed to the temperature desired. They are constituted of a mold body (3) that has an impression (4) in which the plastic and/or composite material (2) is arranged.

[0037] According to the invention, the heating means (MC) directly heat the material to be transformed (2) or an intermediary surface impression (5) located at the interface between the material (2) to be transformed and the impression (4) of the mold body (3) without using the thermal conductivity of the mold body (3) and/or of the impression (4).

[0038] Thus, contrary to the metallic and composite molds from the prior art which heat the material (2) by heating the mold body (3) that then transfers its heat to the material (2) by thermal conduction, the molds of the invention have heating means (MC) that only heat the material or an intermediary surface impression (5) that is in direct contact with the material, without using the thermal conduction of the mold body.

[0039] To this end, according to a first embodiment, the heating means (MC) are of the electrokinetic type, with Joule effect, for example, as shown in FIGS. 2a-2 d, and consist of directly sending an electric current through the plastic or composite material if the latter is electrically conductive, or through an intermediary surface impression (5) if the material (2) is not conductive, said impression being made of an electrically conductive material. The circulation of the current causes the heating of the material (2) or of the impression (5) adjacent thereto due to the resistance of the material or of the impression, but in no way acts on the mold body (3).

[0040] According to other embodiments of the molds shown in FIGS. 3a-4 d, the electric current circulating in the material (2) or in the surface impression (5) is a current induced by magnetic fields (40), and the heating means (MC) are of the magnetodynamic or induction type, the current induced acting similarly to the first embodiment in order to cause the heating of the material (2) or of the surface impression (5).

[0041] According to the first embodiment of the molds and its variants, shown in FIGS. 1-4 d, the latter are formed by a mold body (3) made of two portions: a lower portion (3 a) or lower baseplate that has a recessed impression (4 a), and an upper portion (3 b), also called a punch, that has an upper impression (4 b) in relief, the upper and lower impressions forming the impression (4) of the mold.

[0042] According to a second embodiment shown in FIGS. 5-8, the molds (1) are adapted to make hollow sections and have a mold body (3) made of one or several portions (3 a, 3 b) that each have recessed impressions (4 a, 4 b) defining the outer form of the section. According to this embodiment, the mold (1) uses an inner inflatable flexible envelope or lining (150) in order to make the inside of the section, as known and as shown in FIGS. 6a-7 d.

[0043] Once the plastic and/or composite material (2) is arranged in the lower impression (4 a), the mold is closed and the lower (4 a) and upper (4 b) impressions define the final form that the material (2) will take on during its transformation.

[0044] According to the invention, the lower and upper (4 a, 4 b) impressions are constituted of a material adapted to avoid the transfer of heat from the material (2) to the mold body (3, 3 a, 3 b) itself, and vice-versa. Thus, the baseplate (3 a) and the punch (3 b), or both parts of the mold for hollow sections (3 a, 3 b), have a base made of a rigid plastic and/or composite material, such as a cast resin (6), and they comprise on their opposing surfaces an impression (4 a, 4 b) made of a thermally insulating material (7), such as, for example, mineral resin, this material being arranged to form a layer that prevents the transfer of thermal energy, i.e., in order to form a thermal barrier or shield.

[0045] Furthermore, in certain variants not shown, complementary thermal insulating means can be provided. These means can be advantageously obtained by adding reflective sheets comprising a silver coating, or mica, for example, said sheets being capable of being arranged inside of the insulating material (7) or between said material and the one forming the mold body itself.

[0046] Thus, when the material (2) and/or the surface impression (5) located between the mold impressions (4 a, 4 b) is/are directly heated by the heating means (MC), the impressions (4 a, 4 b) insulate the respective bodies or bases of the baseplate (3 a) and of the punch (3 b) that are only slightly heated, or even not heated at all. As a result, these bases (3 a, 3 b) can be made of a common composite material, such as epoxy resin (6), without being damaged during the transformation cycles, even when the material (2) is transformed at high temperatures (greater than 150° C.). The molds of the invention are therefore of the composite type but, contrary to the composite molds from the prior art that could only transform materials of the thermosetting type at maximum temperatures of 130° C., they can perform the transformation at high temperatures without being damaged, particularly due to their impression (4 a, 4 b) made of a thermally insulating material (7) and to the heating means (MC) that directly heat the material (2) or a surface impression (5).

[0047] According to the preferred embodiment of the invention, the impressions (4 a, 4 b) are made of mineral resin constituted of the association or combination of non-organic constituents, according to several possible methods (polyaddition, polycondensation, sintering, curing, etc.), and are, for example, made of inorganic ceramic resulting from a polycondensation of at least one mineral resin, such as those marketed under the trademarks FIXWOOL (PS4, EZG, AL) or GÉOPOLYMÉRE. These mineral resins can additionally contain fillers (carbon, stainless fibers, alumosilicate) or other additives. When the plastic and/or composite material (2) to be transformed is electrically conductive, the molds (1) have no intermediary surface impression (5), as shown in FIGS. 2a-3 d and 7 a-7 d. However, when the material (2) is not conductive, an electrically conductive surface impression (5) is provided in the mold which is adapted to be heated in order to transmit its heat to the plastic material (2) adjacent thereto by thermal conduction, as shown in FIGS. 4a-4 d, 5 and 6 a-6 d.

[0048] According to the preferred embodiments of the molds, this intermediary surface impression (5) can be obtained by the electroplating of a metal or of several layers of various metals, or by the shaping of a strip made of a forgeable or malleable metal alloy having a thickness comprised between 0.01 mm and 5 mm, for example. It could also be obtained by the machining of steel, alloy or any other metal, without leaving the scope of protection of the invention. It can also be obtained by the heat (plasma) spraying of metals or conductive ceramics, or by the vacuum or chemical vapor phase deposition of metals or ceramics.

[0049] According to the first embodiment shown in FIGS. 1-2 d, the means (MC) for heating the mold (1) are formed by electric copper contacts (8 a, 8 b) that allow passing an electric current directly through the material (2) to be transformed. In the second and third embodiments shown in FIGS. 3a-4 d, the heating means are formed by inductors (9, 9 a, 9 b, etc.) that, through the application of magnetic fields (40), cause the circulation of an electric current in the material (2) or in a surface impression (5) in order to heat them.

[0050] Additionally, according to this first embodiment, the mold (1) has a device for pressurizing the material (2) adapted to be implemented during the heating cycle in order to obtain an even transformation of the material (2) by imparting homogeneous pressure and temperature constraints thereto, regardless of the form of the element to be made and therefore of the impression (4 a, 4 b).

[0051] According to the first preferred embodiment of the molds (1), the pressurizing device is formed by a flexible membrane (10) and by means (11, 12 a, 12 b) for circulating air, namely adapted to inflate said membrane (10). The membrane (10) is advantageously fixed about the impression (4 b) in relief of the punch (3 b) in order to be able to be pressurized by thus taking on the form of the impression. In this manner, it subjects the plastic material (2) to be transformed to the desired pressure in a homogeneous manner throughout the impression, regardless of the form of the impression and therefore of the element to be made. The pressurizing means are advantageously formed by one or several pressurizing chambers (11) located in the body of the punch (3 b) and provided with pressurizing and circulating channels (12 a, 12 b) that connect the chambers to the surface of the impression (4 b) in relief that the membrane (10) envelops.

[0052] According to another characteristic, the molds (1) have means for cooling the material (2) adapted to allow the cooling of the plastic and/or composite material elements (2) so as to facilitate the demolding thereof in particular. These cooling means can be at least partially formed by the pressurizing device (10, 11, 12 a, 12 b) that allows, as shown in FIGS. 2c, 3 c and 4 c, circulating fresh air between the impression (4 b) of the punch (3 b) and the membrane (10). This air, that can be selected to be −30° C., for example, allows cooling the material (2) through the membrane (10) and the impression (4 b) of the punch. Thus, as shown in FIGS. 2c, 3 c and 4 c, the cooling occurs due to a partial retraction of the punch that, while maintaining the pressure in the membrane (10), allows creating a space between its impression (4 b) and said membrane so as to circulate cold air therein. One can note that the membrane (10) can advantageously be made of silicone, or of fluoroelastomer, or any other extensible material that resists high temperatures.

[0053] It goes without saying that other complementary cooling means (13, 14) can be provided, namely means that are capable of cooling the surface impression (5), when it is used, and the layer of insulating material (7) of the recessed impression (4 a) of the baseplate (3 a), the surface of which can be slightly heated as the cycles are repeated.

[0054] These complementary cooling means are, for example, constituted by a separating device adapted to separate the insulating layer (7) forming the recessed impression (4 a) of the surface impression (5) or of the transformed material (2) to allow the circulation of cool air therebetween by means of a system for circulating air located in the baseplate (3 a), as shown in FIG. 4d. According to an embodiment of the separating device, the latter is, for example, made by an inflatable or elastomeric seal (13) arranged in a groove provided to this end about the recessed impression (4 a). Furthermore, an elastomeric frame (14) allows conserving the impermeability of the mold, even during the cooling phase shown in FIGS. 2c, 3 c and 4 c.

[0055] It is understood that to simplify the description, the molds of the invention are described in a simplified diagram in which they are made of two portions, but their form could obviously be complex without leaving the scope of protection of the invention. Likewise, the described heating means that heat the material (2) or the surface impression (5) are of the electrokinetic or magnetodynamic type; however, they can also be of another type.

[0056] According to a second embodiment and its variants shown in FIGS. 5, 6a-7 d and 8, the molds (1) are also provided to make hollow sections. Therefore, they comprises a mold body (3) that is advantageously formed of several elements (3 a, 3 b), each having a recessed impression (4 a, 4 b) in which the user arranges the material (2). The material (2) is advantageously arranged about an inflatable envelope or lining (150) called a goldbeater's skin, and that is pressurized when one heats the material, as shown in FIGS. 6b and 7 a. According to this embodiment, the heating means can be of the magnetodynamic type, as shown in FIGS. 6b and 7 a, or of the electrokinetic type, as shown in FIG. 8, or other. The molds also comprise an impression (4 a, 4 b) made of a thermally insulating material (7) and have a surface impression (5), depending on the type of material (2) to be transformed (electric conductivity).

[0057]FIG. 5 and FIGS. 6a-7 d show a mold (1) using magnetodynamic heating means formed by inductors (9 a, 9 b), a first variant showing the transformation of a non-electrically conductive material (FIGS. 5, 6a-6 d) due to the surface impression (5), and a second variant shows the transformation of a conductive material (2) in FIGS. 7a-7 d. One can note that in these embodiments, the cooling means are obtained due to a device for circulating fresh air that allows establishing an air circulation at a pressure P2 that is greater than the pressure P1 that exists in the goldbeater's skin (150), as shown in FIGS. 6d and 7 c. One can also note that the complementary cooling means that are not shown could also allow the cooling of the surface impression (5) and/or of the outer surface of the insulating layers (4 a, 4 b) by separating them from the mold body, as shown in FIG. 7d.

[0058] According to the invention, the layers (4 a, 4 b) of insulating material (7) and the mold body (3, 3 a, 3 b) are assembled by any type of binding, such as gluing or mechanical fasteners of the insert type. These binding means can also allow the attachment of the surface impression (5).

[0059] Furthermore, it is important to note that the molds (1) can be equipped with means for controlling the temperature that are capable of precisely measuring or evaluating the temperature of the material (2) and/or of the surface impression (5). These means can be obtained by a measuring orifice (151) that is advantageously conical, in which a laser-sighted apparatus (152) performs an infrared measurement directly on the surface impression (5), as shown in FIG. 6c, or on a tab of material having a high thermal conductivity (153), such as a mineral resin loaded with a copper-beryllium alloy, for example, as shown in FIG. 7b. However, these control means could be obtained differently, for example, according to the variant shown in FIG. 8, in which the heating means are of the electrokinetic type, formed by electric contacts mounted on copper blocks (155 a, 155 b) located at the ends of the semi-cylindrical mold portions, the control can occur due to the measurement of intensity of the electric current crossing through the material, said intensity being dependent on the temperature of the material.

[0060] Furthermore, the invention also relates to a method for transforming plastic and/or composite materials, such as thermoplastic or thermosetting polymers, or vulcanizable compounds, associated with the previously described molds (1). In a main step shown in FIGS. 2a, 3 a, 4 a, this method consists of directly heating the material (2) to be transformed or a surface impression (5), without using the thermal conductivity of the mold body. In addition, this method also comprises a complementary step for pressurizing the material, due to the inflatable membrane device (10, 11, 12 a, 12 b), as shown in FIGS. 2b, 3 b and 4 b, followed by a phase for cooling the material (2) by circulating cold air, as shown in FIGS. 2c, 3 c and 4 c, and a demolding step shown in FIGS. 2d and 3 d. This demolding phase can also be accompanied by a complementary step for cooling the surface impression (5), as shown in FIG. 4d.

[0061] Also, one can note that the surface impression (5) and/or the impressions (4, 4 a, 4 b) made of material forming a thermal barrier (7) can be removably arranged in the mold (1) by means of adapted attachment means so as to be replaced when they are damaged or worn out without replacing the entire mold body (3, 3 a, 3 b).

[0062] Naturally, the invention is not limited to the embodiments described and shown by way of examples, but it also includes all of the technical equivalents as well as their combinations. 

1. Mold (1) for transforming plastic and/or composite materials (2), such as thermoplastic and thermosetting polymers and vulcanizable compounds, of the type comprising a mold body (3, 3 a, 3 b) provided with an impression (4, 4 a, 4 b), and which comprises heating means (MC) that directly heat the material to be transformed (2) or an intermediary surface impression (5) adjacent to the material (2) without using the thermal conductivity of the mold body (3 a, 3 b) and/or of the impression (4, 4 a, 4 b) for heating the material to be transformed, whereas the impression (4) is constituted of a material (7) that prevents the transfer of calorific energy from the material (2) to the mold body (3), and vice-versa, said material (7) forming the impression (4, 4 a, 4 b) being a mineral resin constituted of the association of non-organic constituents, characterized in that it comprises complementary insulating means arranged in the material (7) forming the impression (4, 4 a, 4 b), or between said material and the one forming the mold body (3, 3 a, 3 b).
 2. Mold (1) for transforming plastic and/or composite materials (2) according to claim 1, characterized in that the complementary insulating means are formed by at least one reflective sheet arranged in the material (7) forming the impression (4, 4 a, 4 b), or between said material and the one forming the mold body (3, 3 a, 3 b).
 3. Mold (1) for transforming plastic and/or composite materials (2) according to any one of the preceding claims, characterized in that the heating means (MC) are of the electrokinetic or magnetodynamic type, and send an electric current directly or by induction through the material (2) or through the surface impression (5).
 4. Mold (1) for transforming plastic and/or composite materials (2) according to any one of the preceding claims, characterized in that it comprises a surface impression (5) made of an electrically conductive material and arranged between the material (2) and the impression (4, 4 a, 4 b) in order to cover said impression at least partially.
 5. Mold (1) for transforming plastic and/or composite materials (2) according to claim 4, characterized in that the surface impression (5) is made by electroplating a metal or several layers of various metals, by machining a metal or an alloy, or by forming a strip made of a forgeable or malleable metal alloy, by plasma spraying metal or conductive ceramics, or by vacuum or chemical vapor phase deposition.
 6. Mold (1) for transforming plastic and/or composite materials (2) according to any one of the preceding claims, characterized in that it comprises a mold body (3) made of two portions (3 a, 3 b), a lower portion or baseplate (3 a) that has a recessed impression (4 a), and an upper portion or punch (3 b) that has an impression (4 b) in relief.
 7. Mold (1) for transforming plastic and/or composite materials (2) according to any one of the preceding claims, characterized in that it comprises a device (10, 11, 12 a, 12 b) for pressurizing the material (2) to be transformed which has a flexible membrane (10).
 8. Mold (1) for transforming plastic and/or composite materials (2) according to claims 6 and 7, characterized in that the membrane (10) is arranged about the impression (4 b) in relief in order to be pressurized due to means (11, 12 a, 12 b) for circulating air.
 9. Mold (1) for transforming plastic and/or composite materials (2) according to claims 7 or 8, characterized in that the membrane (10) is made of silicone, of fluoroelastomer or any other extensible material that can withstand high temperatures.
 10. Mold (1) for transforming plastic and/or composite materials (2) according to any one of the previous claims, characterized in that it has means for cooling the material (2).
 11. Mold (1) for transforming plastic and/or composite materials (2) according to claims 9 and 10, characterized in that the cooling means are at least partially formed by the pressurizing device (10, 11, 12 a, 12 b) that allows the circulation of fresh air between the impression (4 b) and the membrane (10).
 12. Mold (1) for transforming plastic and/or composite materials (2) according to claim 4, characterized in that it comprises complementary cooling means that separate the surface impression (5) and/or the material (2) from the impression (4) of the mold to allow the circulation of fresh air therebetween.
 13. Mold (1) for transforming plastic and/or composite materials (2) according to any one of the preceding claims, characterized in that the mold body (3, 3 a, 3 b) is made of cast resin.
 14. Method for transforming plastic or composite materials (2), characterized in that it comprises a main step that includes directly heating, in a mold (1), the material (2) or a surface impression (5) adjacent thereto, without using the thermal conductivity of the mold body. 